Method of making refractory masses and batch



Patented July 28, 1953 U N I T E D:

OFFICE 24 Claims. 1.

This invention relates to basic'refractories and. more particularly to a method of producing such refractories at low temperature' byyreaction in situ of selected material.

In prior applications Serial-Numbers84,345, 5

filed March 30, 1949, now-Patent'No'. 2,621,131, December 9,1952, and 134,930-filedDecember-'24,; 1949, now Patent No. 2,599,184, June-3, 1952, covering the use of preformedornatural. low-.

(Cl. IDS-58) 2, equilibrium with all the silicapresent, the ortho-- silicate-containing, only-the basic oxide in questiona Thesecondutypeconsists of "starting materialforthe non-refractory silicate, and the formation. .of ,the non-refractory silicate in situ is. ensured. by the provision inv the over-all 'mixture otsuch grainsizes of reactants that the surface areanof thejfree and combined silica is at,.least'.42%,ofithe total surface area of the melting silicatesfor bonding granular materials --non-.volatile constituents of all the particles,

consisting essentially of (1) lime, magnesiaand' silica, and (2) magnesia, alumina andsilica; respectively, it has been emphasized that in'th-e practice of these inventions one must-carefully:

avoid reaction between fine portions of-the:re--

particles firmly together. It is pointed out-that this difficulty can be avoided'by either-omitting the finer particles of the refractoryconstituent or by adding the non-refractoryconstituentitself in granular form.

Strangely enough, it :has now been foundthat" 5- in consolidating.granular partic1esof suchrefractory material advantage canibe-taken of this; very, tendency of fine particles-$01reactwith one another much more rapidlyrthan do coarset-pare ticles; Indeed it has-been; foundsth-atsmarkedw341;

technical and economicadvantages are-obtained by forming the non-refractoryconstituent situ'. in the granular particles;

Essentially, the invention is a simplified metha 0d of making refractory masses and shapes which 35;;

comprises heating an intimate m-ixture-of twowidely different types of materials. The first type consists of relatively; coarse granular ipam ticles containing an alkaline earth (reactive basicr stantia-lly without alumina, but withonwithout magnesia and (2) magnesia, inthe-substantialnabsence of lime, and with or without alumina. All of the alkaline earths: (magnesia, lime;

strontia and baryta) form both refractory orthov- A 451? silicates and non-refractoryor-eutectic silicates which melt below 1550- C. Thercactive :loasic"v oxide must always be present-in. the'granularfi. material in amount at=.least;6%-by weight-inn that is, the initial'reaction product'is a nonrefractorysili'cate containingat least 42% silica. The two types of material are so proportioned and mixed that the amount of silica in the mixture is nomore than will combine at ultimate equilibriumito "form the orthosilicate containing only; the basic oxideini' question: The'mixture is 'thenheated," and reaction takes place in two distinct stages, the first of which is essentially the'formati'omand' fusion of the non-refractory silicate in' situ; The liquidthereupon coats the refractorygranules, and, upon further heating, there follows the-second stage, in which reaction occurs between the liquid and excess reactive-- basicoxidelathe-granules, whereby the liquid is" 'itselfsubstantially eliminated -by conversion into the-corresponding refractory silicate, and the-granules-are bonded into a consolidated and highly refractory mass.-

Not only has it thus become readily possible to form and meltthe non-refractory silicate in situ'; but; by thepropencontrolof grain size, onecan asdesired vary overa wide-rangethe course of thereactionsand the properties of the 7 composite-massor'shapasuch as the temperature at which bonding or setting will begin, the com-- position and-amount-o-f liquid formed-, the viscosity ot the liquid, the-range of temperatureduring which'the plastic conditionof the com oxide), including particularly, (1)-- lime, Sub-1" 4Q-".. posi-t -mass==will persist, and eventhedensity and' oth'er: physical properties of the ultimate product;

In norder to -explain the method-by which this invention can becommercially applied to a wide Variety Of'JreiIactOry.: materials, with very strik ing. results-,= it is-nesirableto first set out as fully ass possiblec thea. funda-mental.v principles upon;

ztherimzenti'omiis based; These principles are in part well known; but imtheirrelation to= excess or that required,.to --.formaat: ultimateafi the bonding of refractory;materials-they have largely been evolved as a result of experiments carried out over a period of several years, together with a continuous attempt to explain the results obtained by consideration of the phase equilibrium diagrams involved. Whether wholly accurate or not, they will serve as an adequate guide in the practice of the invention by those versed in the art. They will later be supplemented by numerous examples illustrating particular applications of the principles in question.

1. When silica and a basic oxide with which it can react in the solid condition are mixed and heated, the rate of reaction occurring in the initial stages depends upon the area of the surfaces of actual contact between the reactants. It is for this reason that fine particles react so much more rapidly than do coarse particles.

2. For any two solid reactants heated in contact, the contact surfaces are equal, and prior to liquid formation there is consequently a tendency for them to react in proportion to the weights corresponding to equal surfaces; this tendency,

(b) Increase in amount of liquid, without complete melting.

(0) Solution of one solid and simultaneous precipitation of another the limit of solubility of which has been reached.

(d) Complete solidification.

(e) Steps 1) and c, or b, c and d, occurring in more or less rapid succession.

6. With three or more reactants, the course of reaction is similar except that selectivity is more likely to play a part. When lime, magnesia and silica are the reactants, preferential reaction of lime and silica occurs both in the initial and final stages, and the selectivity is of two different types. When fine silica reacts with coarse dolomite, the eutectic melting at 1321 C. (containing 61.5 silica, 30.5 lime and 8.0% magnesia) is formed first, even though this involves the selective extraction of lime from the lime-magnesia' complex. Ultimately, when this eutectic reacts with a large excess of dolomite, all the magnesia appears as periclase, along with trihowever, may be overbalanced in the solid condition by the higher heat of formation of a particular compound of the two reactants, which is thereby preferentially formed.

3. When two oxides which are potential reactants are mixed and subjected to a rising temperature, they tend to form liquid at the lowest temperature possible, and this may be the melting point of the lowest-melting eutectic in the binary system. If, however, a compound has already been formed, the temperature of initial liquid formation may be the melting point of some other eutectic. For example, in the case of lime and silica there is a strong tendency for highly refractory dicalcium silicate to form during a long period of heating at a relatively low temperature; since there are several compounds and eutectics in this system, the eutectic liquid which subsequently forms depends upon which oxide is present in excess and the amount of that oxide.

4. The course of reaction between two oxides may depend upon the rate of heating. Slow and protracted heating below the melting point of any eutectic in the system tends to promote the formation of a compound, whereas, with very rapid heating, melting of the eutectic usually occurs before compound formation can proceed to any considerable degree, in which case the quantity of liquid existing at any given temperature is normally much greater than with slow heating.

5. Once liquid has been formed from two oxides, it begins to react with or take into solu tion as much of the remaining solids as can be absorbed at that temperature, and the course of reaction or absorption is largely determined by the relative surface areas of those solids. If, for example, very coarse lime be mixed with a small proportion of silica so finely ground that its surface area greatly exceeds that of the lime, the course of reaction is towards the formation of a more siliceous liquid as long as the surface area of the silica predominates; when the silica has nearly disappeared and the surface area of the lime in turn predominates, the course ofreaction is reversed and the liquid becomes more basic until no more solid can be absorbed at the temperature in question. In the general case, depending upon the conditions prevailing, any of the following may occur:

(a) Complete melting.

calcium silicate and free lime, the magnesia which had been in combination being set free in the process. With three reactants, the early precipitation of a relatively refractory intermediate or end product occurs more frequently than when only two are present.

7. When reaction occurs between granular solids at such a temperature that little or no liquid is formed at any time, the product is not strongly bonded, either hot or after cooling.

8. When considerable liquid is formed in a mass of granular materials, the cooled mass possesses a strong bond and is well consolidated. The useful range has been found to be 6-30% by weight of the refractory material to be bonded.

9. Upon heating granular materials of the type herein described, the normal course of reactions as determined by periodic examination of the heated mass with a poker or other sharp instrument is as follows:

(a) Development of stickiness and plasticity as initial liquid forms, mainly from the finer ingredients of the mass.

(1)) Increasing stickiness with the formation of more liquid.

(0) Decreasing stickiness and increasing hardness as the liquid reacts with the coarser refractory granules and is itself converted to refractory compounds which are solid at the temperature in question.

((1) Ultimate development of a highly refractory mass which, even at 1600-1700 C., is hard and strong and shows no evidence of the presence of liquid. This strength is normally preserved when the mass is cooled to room temperature. In the case of dicalcium silicate formation, dusting and disintegration may occur on cooling unless a stabilizing agent such as boric acid is added to prevent inversion from the beta to the gamma form.

10. Although the importance of the relative surface areas of the reacting oxides will be clear from the above, a practical method of calculating such areas is still required for the application of this invention.

The determination of the relative surface areas of reactants is based upon their screen analyses.

Any screen scale may be used, but as an illustration the widely adopted Tyler scale, based on the principle of square openings each twice the area of the next smaller size, will be taken. It will be assumed that the average diameter of the particles which have passed through a given ammo-ea:

screen and been retained onthe next smaller or" the-seri'es-is greater than the diameter-of the smaller opening by one-third of the differencebetween' th'e twov While it is recognized that this relation'will vary somewhat with each screen analysis, it has proved-asufliciently close approximation for the purpose. Further, the method is satisfactory" whether the; screens of the-- Tyler series areall used orevery second Joneisomitted. In fact, so 'great is the relative surface-area of very fine-fractions that; neglecting any greater refinement, it has been found satisfactory I to take theaveragediameter of all 1 the material passinglOO'mesh as 00020- '(0.05 1mm).

In the accompanyingtable'there are *listed the mesh sizes most commonly used for refractory materials, and the corresponding linearmeasurements'of 'the-actual Tyler openings: Fromthese,

the averagediameter-"has beencalculatedfor particles passingone and-retained-n"the next succeeding screen of the series, using the'assumptions given above.- Irr-the final column, the relative areas'per unit weight of particles'of the given size are shown, these" areas being inversely proportional to-the diameters in question, a relation that 'holdsrigidly'for particles of any given shape. For convenience, the size passing /3 (9.42 mm.) andretained on 3 mesh has been taken as unity.

Openm in Eitgggitlgd Relative Mesh; Particle Size Driarticge 2 2? lame er Inches Mm. Inches Weight \+3 111-- 1 0. 2990 w 1. 00 3 mesh 0. 263 6. 680

3+4J 0, 2110 1. 4-2 4 mesh 0. 185 4.699

6 mesh.r 0.131 v 3. 327' 6+8 0. 1057 2. 83 8 mcsh; 0. 093' 2. 362

-8+10 0. 0743 4. 02 10 mesh 0. 065 1.

10+14 0. 0523 5. 72 14 mesh i. 0. 046 1. 168.

14+20 0. 0362, 8. 26 20 mesh 0. 0328 0. 833

2Q+28 0. 0264 11. 33 28 mesh 0. 0232 0. 589' 28+35 0.0187 15. 99 35 mesh-n- 0. 0164 0. 417.1 I

48,-i-65 0. 0093 1 32. 15 65mesh: 010082 0. 208

65+l00 0. 0066 45. 30 100 1nesh. .1. 0. 0058 0.141

100 mesh; 0. 00193 154. 92

100+150 0.00467 64. 03- 150 mesh- 0. 0041, 0.104

200 mesh; 0. 00097- 308. 25

Because of the many. practical applications which can be made of the method described, and the necessity-10f. distinguishingclearly between theatechniqu'e required in the practice of-the in- 1 vention and those procediu'es-which' fail to achieve satisfactory bonding, it .is desirable-to= amples or" the many variations permissible with-- in the scope of the inventiona To further emphasize the difference in techniques, the three examples of; 5 failure: torv apply the-principleseor-the inventionrand-theifirst nineexamples; successful methodsrwilh alkgutilizer developed.

the same raw.materialsin; th'ersameaproportionss by weight, but, becauseofi'variationsriim grain-: sizeand consequently :in relativevsurface-,iareaaz the reactions occurring will fcllow a numb'errot: different courses. 1

The raw materials chosen are hard-burned (the so-called double burned) dolomite, and quartzite. Both of these materials are cheaply available of 'a'purity ranging-from upwards. andfor the sake of simplicity all impuritieswill'zi be neglected; the dolomite beingtakenras-cone taining 58.2;Ca0 and 41.8 MgO; and the quartz'e. ite as S102. Both materials.iaretavailable" as" crushed to about (9.42"mm;) maximum? size, and they are to be used in' the proportions byweight of 92.6 partsofdolomite and'7l4 parts of quartzite; If fullyreacted', these 'will form' in'i each case about 28;-'1%' tricalc'ium silicate andf leave-33.2% of free lime-and 38;7%z;of freeizmagir nesia. as periclase.

EXAMPLE l For use-as a fettling material in anopenhearth furnace the dolomite and the silica' are 'crushedrf to pass (9.42 mm.) andare then thoroughly? mixed and thrown into the hot furnace in the'v desired position. Since the two-materials haver almost identical screen analyses; the amountpi" dolomite of any given screenfraction is. on thev average 12.5 times-that of thesilica (92.6/7Air;

and their 1 surface areas are in the' same proportions. As reaction occurs,- traces of low-meltin'g, liquid are formed around each particle of silica, large or small, but, blacauseof the large quantity of fine dolomite immediatelyavailable;reao

tion with it to refractory silicates is almost instantaneous, andnoappreciable amount of liquid exists at anyone timer. Onuaccountiofpthes coarseness of the reactants, equilibrium is reached. (if at all) only after a long period of .heatingaatra which time patches of tricalcium silicatelpresurnably surrounding someorthosilicate) are'distributed-throughout the mass, but no appreciable: shrinkage has occurred and no general bondhase Because of failure to practice the teachings. of the invention,...the iobiectivesrahave not been reached.

EXAMPLE '2' The result is even worse than that of Example 1...

EXAMPLE 3 Both reactants are now 'crush'ed to passalflfl mesh, and are slowly heated to *1650 C5, the" highest temperature of the open hearth furnace and held at that point for one hour: Asin ample 1, the surface areas of the two constituents" are again proportional to their respective weights;- Since there is a large excess of lime available fo'rr combination with .the silica; these" oxides selec tively react in preference to magnesia and-silicate as explained above, and the tendency-is to -form a silicate with a high lime-silicaratio: Fdnreasons which are not whollyclear, the orthosilicate actually begins to. form first, and this evenat --a= temperature far below the-melting: point ofi'any: of the possible binary or ternary eutectics. How ever, being in contact with excess lime at 16509, the silica. ultimately-reacts totricalcium silic'atee leaving. all: the -magnesiai and muclr of 7 still free, as already explained, and, since no appreciable amount of liquid has existed at any one time, the mass as a Whole is soft and friable. The results will obviously be similar if any other straight crush of both reactants be used.

EXAMPLE 4 In this case the dolomite is first crushed to about 3 mesh, a suitable size for fettling steel furnace banks, and the minus 8 mesh material is removed by screening and is ground to pass 100 mesh, as is also the silica. It is decided to use as a bond the lime-magnesia-silica eutectic melting at 1321 C. and containing 30.5, 8.0 and 61.5% of the three oxides, respectively. It is then necessary to calculate the required surface areas of the dolomite and silica. Since, when dolomite is used, there is bound to be an excess of magnesia over that of the eutectic composition, only the lime and silica need be considered as initial reactants. Their proportions by weight are 30.5 and 61.5, and in the ideal case these should also be their relative surface areas. Since, from the above table, the minus 100 mesh silica has a surface area of 155 units per unit weight, the total area is 7.4 155, or 1147 units, and 1147 (30.5/61.5) units are required for the lime, or, of dolomite, (1147/0582) (30.5/61.5), that is, 976 units. The following tabulation shows how the surface area of the coarse dolomite is calculated from its screen analysis:

Screen analysis 'Each unit of coarse dolomite therefore has 1.9 units of area, while each unit of dolomite crushed to pass 100 mesh has 155 units. A simple algebraic calculation shows that, in order to provide 976 units of area, there are then required 87.37 parts of coarse dolomite and 5.23 parts of fine dolomite; these furnish 166 and 810 units of area, respectively.

The above calculation has been given in detail as an' illustration of the method used, but, since the 5.23 parts of fine dolomite provide 83% of the required surface area of dolomite, it is obvious that no detailed calculation of the surface area of the very coarse material is necessary. Actually, the results are quite satisfactory when the coarse fraction is entirely disregarded and 6.3 parts of fine dolomite are used to provide the 976 units of surface area. This procedure is permissible when, as here, the coarse particles are on the average, of the order of 100 times the average diameter of the particles in the fine fraction and the objective is a highly siliceous liquid.

When the mixture of coarse and fine dolomite and fine silica is subjected to a rising temperature, as in a laboratory test or on the banks of an open hearth furnace, liquid formation occurs and is readily observable as initial fritting at almost exactly-"132? C., the melting point of the eutecticwhosecomposition was the objective.

The-liquid formed-(7.4/0.615 by weight, or rough-' 8. ly 12%) rapidly coats all the larger particles, and as the temperature is raised a series of reactions occur until the pasty mass becomes hard and strong, even at the highest furnace temperature. This condition persists upon cooling.

EXAMPLE 5 In this case a finer dolomite, crushed to pass 6 mesh, is to be bonded at as low a temperature as possible. Since the average particle size is close to half that of the previous example, one may simply remove the minus 16 mesh fraction and grind this, as well as the silica, to pass 200 mesh. The relative grain sizes and surface areas are then substantially the same as before, and the reactions occur in a similar way. Bonding may be effected by burning at 1350 C., but a somewhat higher temperature is desirable if the reactions are to be carried to completion.

A mixture of this kind can be used for fettling, as in Example 4. There are, however, real differences between the two cases. From a practical point of view, it is desirable that little dust be formed when refractory materials are thrown into a furnace, for dust may in some cases be carried out with the furnace gases, as in an open hearth, or it may settle in the middle of a furnace instead of on the banks where it is wanted, as in an electric furnace. The coarser material therefore possesses one practical advantage. On the other hand, very coarse materials do not set as rapidly or to as dense a mass as do those containing a considerable percentage of fines, hence the second type of material may be chosen for this reason.

Further, the coarser materials will take considerably longer to react fully and eliminate all liquid, and will as a consequence remain longer in a plastic or pasty condition. These cases illustrate how the degree of set, the range of temperature during which the plastic condition will persist and the density of the final product may be controlled by varying the grain sizes of the reacting materials.

EXAMPLE 6 This case is similar to that of Example 5, but the average particle diameter of the coarse fraction is againreduced by 50%, that is, to about 0.04 (1.016 mm). While such a case is commercially unusual, the same procedure as that previously described may be applied if the fine fraction is ground so as to maintain similar ratios of average diameters and total surface areas of the coarse and fine fractions.

EXAMPLE 7 This is a modification of Example 6, and, on economic grounds, may be preferable to the extremely fine grinding there required. In this case no grinding beyond mesh is necessary, but the contact between the finer fractions which are to be the initial reactants is improved by mixing and pelletizing these materials. The constituents then react in the desired order. Pelletizing is not recommended when brick are to be manufactured, but it is satisfactory for the preparation of composite fettling materials for furnaces.

EXAMPLE 8 There exists still another possible method of dealing with the conditions of Example 6, one which may often prove the most economical. In-

ystead of; grinding the silica and part of the dolomite. to .a high degree of. fineness for. admixture -With the coarse dolomite, the-fine dolomite is omitted and the silica .is left suificiently coarse to. provide the desired ratio of surface area be- ..tweenthisconstituent and all of the dolomite.

- Since, as. in Example 4, it is desired to produce :the eutectic meltingat l321 (3., the necessary surface areas of the silica anddolomite are again -..as 1147 and976.

Therelative Weights are 7.4 and 92.6, hence when all the dolomite is taken into consideration the required average diameter of the particle of silica'is surface area. This. modification, which involves :reaction of the .silica with the surface portion only .of the dolomite present,.-instead of with :specially ground and exceedingly fine dolomite as .a more or' less independent constituent, is thus seen to require no very'fine grinding of the silica.

On'the average, however, the silica is still much finer than the dolomite, the ratio being roughly fifteen to one.

EXAMPLE 9 .In using a. mixtureof .dolomiteand silica, in-

of'fine silica, and there milled, without the addition of a heavy crushing medium, until the particles are eroded by gradual attrition and any desired proportion of fine material is formed. By simply stopping the mill'when a screen analysis ofthe product shows the desired proportion of fines, there will be obtained a'self-setting mixture of coarse and fine; material.

In a continuous operation, the rate of-feed is-merely so 'controlled as to obtain in the product the desired .percentageof .fines, which is readily calculated above. .It is immaterial whetherthe silica is .ofgreater'ffineness thanthe fine dolomite pro- :vided that (1) theratio of particle-size of the coarseand'fine fractions of the dolomite is suflicientlygreat .to make them react almost independently, or (2) the total surface area of both coarse and. fine dolomite fractions bears the desired relationlto that. of the silica.

EXAMPLE 10 In' Examples 4-9 the objective in each case was theformation of about 12% of the lime-mag- 'nesiasilicaeutectic melting at I321" C., and this result was substantially attained in al1 cases.

'Usingthe same rawmaterials in exactly the same proportions,however, it is quite possible by regulating thegrainsizes of the constituents to form "a difierent proportion of some other low-melting 'zmaterialtovact" as-xaibond. .It' may be desirable.

' xthereforeregar'ded as marginal.

- other direction.

10 for example, to producea .greater aquantity of liquid of lower viscosity. -Reference-to--the limemagnesia-silica phase equilibrium diagramshows that thereis inthis system aeutcctic melting at 1359 C. and having the composition 29l7 CaO, 20.3 MgO and 50.0% SiOz. Becauseoffits lower silica content, it has aconsiderably lower-viscosity than that of the 1321 eutectic, and when formed from 7.4%. silica and dolomite' it will 'obviously produce 14.8% liquid, ascompared with the 12% of the former cases. 7 These proportions are both within the most desirable range. Using the same method of calculation. as that given in Example 4, theproportionbf minus 100 :mesh

dolomite is merely increased until its surface area (strictly speakingrincluding also the'surfacearea of the coarser dolomite)l bears-the .de'siredmelation to that of the silica. .since-inithis. case there is practicallyno selective action as between lime and magnesia, it isv correct totake' the" total surface area of the dolomitein'stea'd of that of the .lime only, and,.the silica being 50%- of the'total weight, equal areas are required. On"beingheated, a little of'the'1321eute'ctic is'un'doubtedly formed first, but as soon as the temperaturejrises sufiiciently this quickly passes"over'toitlie"1359 eutectic, because of the additional? fine lime' and magnesia present/"and 'ffective "bonding"'subsequently takes place.

' EXAD/IPLE 1 1 This example has been chosento define'one approximate limit of the range in 'which this method can be satisfactorily used in nbonding granular dolomite with silica. That-limit,-=howeverfisnot inherent inthamethod ofreaction to form liquidinsitu, butarises rat-herIfr-om-the fact, brought out in the previous applications,

that the low-melting constituent should --itself be substantially all liquid atv 1500'C. in order to constitute a satisfactory, bond "for =re'fractory granules of dolomite. 'lfn the present-case'this requires a silica content of approximately "42% in the low-melting constituent. 'Such 'a'bond can be'formed in situ'by using with "714partsof minus 100 mesh'silica 92:6 parts "of dolomite'of such a grain size that the surface area wilPbe 58/42 of 1147, or 1584 units. Trial has shown that, while reaction of these constituents does readily occur inthe manner desired, the bond is not strongly developed as with low-melting constituents -higher in silica, and this case is The method is applicable down to 42% silica, but not below. This limit is of course thesame as that of the surface area of the silicarelative to the total surface areaof all. particles in the cemplete; mixture.

EXAMPLE 12 There remains a for consideration in the a series of dolomite-silica combinations a' ver y important which represents theextreme limit-inthe That =extreme is the :use of 7.4% of fine, free sil-ica wi-th coarse-,=hard-burned dolomite of "any commercial grainrsizeihavi-ng littleor 'no'fine fractionpresent. Actually, if anywhere-from--about 5-to 15% of-"fi1re 8ilica be used, and fine dolomite-he substantially absent,

good bcndingis secured. Thissurprising: result 11 proportion of silica reacts with a relatively small proportion of dolomite), a little of the 1321 eutectic is still formed. At any temperature higher than this, solution of the remaining solids begins, and base and acid at any particular time react in'proportion to the instantaneous values of their surface areas.

. Then the course of reaction is reversed, and as the siliceous melt coats the coarse dolomite particles it continues reacting with them until its composition has passed, with increasing quantity of liquid, through the low-melting areas in which the 1321 and1359 eutectic lie, and finally into the area in which refractoriness increases rapidly towards final equilibrium. When 7.4% of silica is used, the ultimate products are exactly as before.

' ing agents for basic refractory granular materials.

The application of this particular principle, although ordinarily avoiding the necessity for anything but a rough estimate of the surface areas of the reactants, is not in all cases superior to the techniques described in previous examples,

, for, in the use of a relatively large amount of coarse basic refractory material and a small amount of fine, acid reactant, there ordinarily results a product of higher porosity, which for some purposes is less serviceable than denser material derived from a wider range of grain sizes.

coarse particles glazed that when the mass was kept under water for 48 hours the amount of slaking occurring was almost negligible, in spite of its high content of free lime.

It is evident that, if desired, one can make up a large quantity of a mixture of 7.4 parts of fine silica and 10.2 parts of fine raw dolomite, which will keep indefinitely without deterioration, and use this as required in admixture with coarser hard-burned dolomite. Other proportions may sometimes be advantageous.

EXAMPLE 14 On some steel plants raw dolomite from which the fines have been removed is largely used as a fettling material for open hearth furnaces, but of itself this does not set in position, and therefore usually affords only temporary protection to the banks, being carried off by the slag and having to be replaced at the end of every heat.

Much greater stability can be secured by utilizingthe same principle as in Example 12 and incor-l porating in such dolomite about 5-10% of fine silica. In order to reduce segregation and dustiness, it may be desirable (l) to apply the mixture wet, with or without a temporary bond, in order to make the fines coat the coarser particles, or (2) to pelletize the silica. If the latter course is adopted, it is preferable to use a mixture of 7.4 parts of fine silica and 10.2 parts of fine raw dolomite, in order to form the 1321 eutectic in situ prior to reaction with the coarse dolomite, as in Example 13.

EXAMPLE 15 In all of the above examples free silica has been used as the siliceous material. Frequently, however, it is more convenient or economical to use other raw materials. For example, there are available in the Province of Quebec two waste products, neither of which is itself of the most desirable composition for use as a low-melting constituent, but which, finely ground and mixed together in suitable proportions, are excellent starting materials for the formation of low-melting eutectics in situ. These materials and their approximate compositions are as follows:

I 050 I MgO SiOz A1103 FeO l P205 L. O. I.

A. Phosphorus furnace slag 47.4 0.5 44.1 4.0 0.2 1.2 0.0 B. Asbestos waste (mostly serpentine) 1.0 38. 0 38.0 1. 5 8. 0 l3. 6 Mixture of 55% A and B (calculated dead-burned basis) 28.7 18.8 44. 7 3.1 4.0 0.7

EXAMPLE 13 In all of the previous examples one of the raw materials has been a hard-burned dolomite, such as is commonly used in fettling open hearth and electric steel furnaces. The method of bondin by reaction and liquid formation in situ is also equally applicable to mixtures containing raw dolomite, which when pure contains 30.4 lime, 21.9 magnesia and 48.7% carbon dioxide. Using the methodof calculation given in Example 4, it is evident that to form the same 1321 eutectic and final product one must use with 7.4 parts of fine silica 925/0513 or 180.6 parts of raw dolomite, of which 170.4 parts may be minus 3 plus 8 mesh and 10.2 parts should be ground to the fineness of the minus 100 mesh silica. In other words, one considers only the one-volatile oxides present. The raw dolomite and silica were strongly bonded after heating to 1400 C. and cooling to room temperatures. The product was undesirably porous, but so thoroughly were the 75 One secures as the product of reaction of 55 parts slag (essentially calcium metasilicate) and 45 parts asbestos waste in .situ a low-melting composition which, on the basis of its principal constituents alone, contains 31.1 lime, 20.4 magnesia and 48.5% silica, proportions very close to those of the 1359 eutectic, which has the composition 29.7, 20.3 and 50.0%, respectively. The presence of the minor oxides will brin about fusion at a slightly lower temperature, yet they are not present in suflicient quantity to affect appreciably the composition of the final product when, say, 5.5 parts of slag and 4.5 parts of asbestos waste as minus 100 mesh constituents are mixed with parts of relatively coarse burned dolomite. Excellent bonding results when these are burned together. Raw dolomite may also be used as the refractory granular material.

Other magnesium silicates, such as olivine, talc, forsterite and enstatite may be substituted for fib$9 waste. When used with calcium metasilicate, ..:in substantially. equal proportions, suitaple: low.---melti-ng.'compositionstareeproduced.

EXAMPLE 16 If it be desired instead to -make vthe 132V eutectic in situ by using the: same raw materials itds. necessary toadd. .alsosome .fineiilicaknng, as calculationshows, the use of 58 parts of-slag,:20 of asbestos waste and 22 of silica yields a product containingthe three major constituentsinithe proprti0ns30.5 lime, 8.7 magnesia and 60.8% silica, which is close enough for all practical purposes to; the composition of v the eutectic,-with 31 .5, 8 .0 and 61.5%, respectively. The overea'll omixture may then consist of 5.8 parts of slag, 2.0 of ashesttos vwaste and 2.2 of silica, ,all ground to 100 "mesh-or finer, and 90 parts of relativelycoarse burned dolomite. The bond developed on burning is fully as good as that of Example 15.

The same eutectic is equally well made in situ .by the use of 40 parts of slag, 42 of silica and 18 of "dolomite, all as fines, which on reacting will j produce liquid containing the three major oxides in the proportions -30.4lime, 8.0 magnesia =-and -"6l".6%-si-lica,-again illustrating how easy it is, to proportion suitable raw V materials so as f to produce substantially a eutectic composition.

EXAMPLE 1'7 I Good: results rare also obtained "when the fme sitions by reaction with the surface portions of the refractory granular particles themselves.

EXAMPLE 18 Liquid formation in situ is-equally well brought.

about in a binary system, such. as that .oflimeand silica, although such cases are usually: of less commercial interest. For example, coarse burned lime mixed with'fine silica and enough'fine lime to give, upon heating-,.a liquidof the l-438 eutectic composition. having-:36 lime and? 645%1 silica-"reacts to form the bond for the coarser lime.

.EXAMPLE 19 Reaction and liquid formation in situare-of at least equal interest in the magnesia-aluminasilica field, where it is possible to utilize the method described for the purpose of bonding granular magnesia. For example, a ramming material can be made iorthe permanentihottoms. 60

' izlaboratoryytests awastcarried rout, .onsminus 100 of open hearth'steelfurnaces :by .comhi ninga-with -'-granular magnesia a. mixture of dzxpartsiof fine v senpentine andffia parts of baIl-iclay'haYin Athe "following compositions v hat-silica: =phase equilibrium idiagramrtha 214 :s..i-8.'7,::ccmpamd mithraltih 611A." lfl;.1:-3,,i respectively, for the l347 eutectic, which is perh-aps the most favorable composition in the system. If the raw constituents cannot readily be bal- 5 .anced. to. the ,desiredpercentage .0i...i.1.i.0.a,.. a l tt free silica may be added, on the one hand,. or. a ..1ess..-si1iceqi1s .claymy be used, on the o he There.;.-;is..available as -..a. coarse material ,(about minus plus 20 mesh) deadeburned granules w of brucite recovered from :rock near NZakefield, i Quebeq and .80 parts on these;arevcombined-with 20 parts of the plastic serpentineeclay m ture 'iandvrammed into; a 'furnaceebottom. 51f desired, .1; small proportion of sodium .-.silicate or other suitablegchemical bond may also be added, but

.witlnag c ndingwclay this s;.:n0t essent l- Upon drying, considerable strength isideveloped, and upon: burning, the 1347 eutectic is first formed in situ and this then "reacts with H the magnesia of the granules to form a highly refractory mixture of periclase, forsterite and magnesiumwaluminate spinel.

.Theretis another desirable utect c'i f t e mat .-nes ia.-,- alumina-.silica .system,.me1ting at, 1362? C. an d containing 25,2121 .,andf respectivelyr 0f @thesethreeoxides. it. may be. formed in situ: i ;..a ,similan way. to; the 11347. eut c .OfiEmll p 19: by. combiningabopt. ecualparts fffi e O ivi e .and kaolin with granular seawater magnesia or other material, ofsimilar composition crushed to a suitable (always relatively coarse) grain a size. "t-Howevemwhen the l347-i-weutectidis termed and this subsequently reacts; rwithzvma-gnesia, a considerable propont-ioncofathe1362eeutectie i always producfiiir hence the' ilatteradstseldemi Ithe 1 primaryiobjective.

lt :is @clear from; a. study of the magnesia-salami- :able 'lowemelting liquids? maybe iormediin the reaction of other raw materials than those given in Examples 19 and 20. Forsterite, enstatite or talc may be substituted for the magnesia- :bearing serpentine of; Example 19, and calcined clays or ibrick grog for. the alumina-bearing ball :clay. .,Substantially equal proportions of each .z-typc ctsilicate 'wi'lli 'sti produce;thepsefuliow- ;mel-ting compositions, and finaLa'dJ'ustmerrtsz-may qbe made; if desired by the additiongoimagnesia, ;si1icar;or1aluminous materials imsuitable propor- .tions.

It will: be observed th-at'in Examples1r'15-s20; the istartine materials terthe non refracto lilieate ;must be so fine that they=react with'one another :practically independently of the coarse aggregate.

EXAMPLE 21 111 -ierder -:to-..: obtain ei sfonma ticn,-,a-- series of .OaO MgO: 'ssior A1205 ..Fe0 i Alli. no.1

isiserpentme 1.0 41.5 .41-5 0.5 4,,3 B. B ll'Cla essentiall aluminum siligateyjif ngi n u n h as as: was: 12284 to 1.0 as xt 042 A andfis ea c a- I 1 ftd ge abfiled basis): 0.3 19.2; "59.3' 18.1 1 ;2

In this mixture the magi-iesia, silica andrallumina are present in the proportions 20.,-61;3',and

flnfiiantjaut a.:.ccanse: fraeticneof.idelemitersv s admitted;.tb 'silriaeeiareai. .2

: l 1y increased. The following results were obtained:

ly, for after initial liquid formed, at 1321 C.,

both of the remaining solids (silica and dolomite) Test No 1 2 3 4 5 Dolomite (9.42 mm.) M, Relative Surface Areas:

m reaction point (=percent total surface area).

Observations on burning to 1400" C. and cooling to room temperature.

Very good bond, se-

vere glazing, very porous.

Very good bond, se-

Obscrvations on burning vere glazing.

to 1500 C. and cooling to room temperature.

vere glazing.

Very good bond, se-

Fair bond, moderate Fair bond, not as Holds together but glazing, relatively good as No. 3 readily friable. nonporous. bqut getter than i o. Verygood bond, mod- Fairly good bond, Friablc, but less so crate to severe glazslight glazing. than at 1400; paring. ticles can be rubbed oil.

. and the fifth was unsuccessful because so much fine dolomite was present that too little liquid was formed, a temperature of 1850 C. being required for complete fusion of the initial reactants.

EXAMPLE 22 In another series of laboratory tests seven mixes were made up in each of which 7.4% of:

minus 100 mesh silica was used with combinations of minus 3 plus 8 mesh and minus 100 mesh burned dolomite, the last two constituents ranging from 0 to 92.6% and 92.6% to 0, respectively. The conditions of the experiments and the results obtained are given in the following table:

continued to be taken into solution until the silica supply was exhausted (at a temperature of 1400 the melt would contain about 62.5% silica), following which dolomite absorption continued through the low-melting composition areas of the 1321 and 1359 eutectics to a silicacontent of approximately 48%, at which point complete solidification resulted at 1400 C. At a temperature of 1500 C., used in a parallel experiment, liquid elimination did not result until the silica content was reduced to about 42%. These cases therefore correspond to Example 12. It may be observed that Test 7 was described as having the best bond of all; because of the paucity of fines, however, the ultimate product was very porous. Tests 4 and 5 were of the best density. Ample evidence was obtained of the selective action of silica with lime in preference to magnesia; had the latter reacted in the full proportion in which it was present, much less of the eutectic liquids Test N0 1 2 3 4 5 6 7 Percent -3+8 m. dolomite 67. 76.9 86.3 87.17 90.35 92.6. Percent -l00 m. dolomite .25

Percent 100 m. silica l00 mesh silica Percent silica at initial reaction point (equal to percent of total surfacearea) 7.4 30.8 50.1 53.2 os.7 86.6. Observationsonbumingto l,400 Soft like dried Poor bond lnsuflicient Goodbond Goodbond Goodbond Best bond 0. and cooling to room temclay. bond. all.

perature.

The results in the first three tests were very poor, because the proportions and grain sizes were such that any low-melting liquid was eliminated substantially as fast as formed, through reaction with fine dolomite having a much greater surface area than that of the silica. All of these illustrate the poor results obtained when the teachings of the invention are disregarded.

Would have been formed and bonding at 1400 would have been less satisfactory.

The above examples of the conditions which do and do not lead to satisfactory bonding of granules of refractory material will, with the discussion of the principles involved, indicate to those skilled in the art how best to obtain the desired results. The limits of the invention, however, need to be more precisely defined.

The discrete or granular particles of refractory material are normally those used in commercial practice in the manufacture of brick, in fettling steel furnaces, etc., the size range of which is from a product which will substantially all pass 8 mesh to one in which the largest particles are 0.75-1.0" (19.05-25.40 mm.) in size. On the reacted in situ to produce it in liquid form, andin the second of which this low-melting silicate is itself substantially eliminated by reaction with the granular particles to be bonded. These granular particles, as explained above, may in some cases themselves contribute one or more of the constituents of the non-refractory silicate, but they nevertheless always remain in substantially their original physical condition, and when they have reacted with the liquid formed in situ are themselves strongly bonded together.

This application is a continuation in part of United States application Serial Number 688,264, filed August 3, 1946, now Patent No, 2,568,237, September 18, 1951.

I claim:

1. A method of consolidating granular particles of basic refractory material containing a reactive alkaline earth which is presentin the said refractory granular material in proportion of at least 6% by weight of the particles in excess of that required to form under equilibrium conditions the orthosilicate of the said alkaline earth with all the silica present, which comprises forming an intimate mixture containing said granular particles of refractory material and, in reactive form, starting material for a non-refractory silicate of said reactive alkaline earth, said intimate mixture containing no more silica than will combine at ultimate equilibrium with the reactive alkaline earth as the orthosilicate, and the total surface area of all non-volatile constituents in said mixture being not more than 2.4 times the total surface area of the free and combined silica therein, heating the mixture to form and melt the non-refractory silicate in'situ and thereby coat the granular particles of refractory material, and further heating the mass to convert the nonrefractory silicate by reaction with excess reactive alkaline earth into a refractory silicate and thereby bond the granular particles into a consolidated and highly refractory mass.

2. A method of consolidating granular particles of basic refractory material containing a reactive alkaline earth which is present in the said refractory granular material in proportion of at least 6% by weight of the particles in excess of that required to form under equilibrium conditions the orthosilicate of the said alkaline earth with all the silica present, which comprises forming an intimate mixture of said refractory material and pellets of finely divided starting material for a non-refractory silicate of said alkaline earth containing at least 42% silica, said intimate mixture containing no more silica than will combine at ultimate equilibrium with the alkaline earth as the orthosilicate, heating the mixture to react and melt the pelletized material, forming in situ a liquid silicate to coat the granular particles of refractory material, and further heating the mass to convert the non-refractory silicate by reaction with excess reactive alkaline earth into a refractory silicate and thereby bond the granular particles into a consolidated and highly refractory mass.

3. A method of consolidating granular particles of basic refractory material containing a reactive alkaline earth which is present in the said refractory granular material in proportion of at least 6% by weight of the particles in excess of that required to form under equilibrium conditions the orthosilicate of the said alkaline earth with all the silica present, which comp-rises forming an intimate mixture containing said granular particles of basic refractory material and finely divided siliceous material containing" at least silica, said intimate mixture containing no more silica than will combine at ultimate equilibrium with the reactive alkaline earth as the orthosilicate, and the total surface area of all non-volatile constituents in said mixture being not more than 2.4 times the total surface area of the free and combined silica therein, heating the mixture to form in situ a eutectic liquid melting below 1400 C. and containing at least 50% silica, and further heating to promote reaction between said eutectic liquid and the remaining siliceous material and basic granular material, thereby eliminating said siliceous material and converting all the silica present into a refractory silicate of said alkaline earth and bonding the granular particles into a consolidated and highly refractory mass.

4. A method of consolidating granular particles of basic refractory material containing a reactive alkaline earth which is present in the said refractory granular material in proportion of at least 6% by weight of the particles in excess of that required to form under equilibrium conditions the orthosilicate of the said alkaline earth with all the silica present, which comprises forming an intimate mixture consisting of a major portion of said relatively coarse basic refractory granular material to be bonded and a minor portion of finely divided and substantially complete starting material to react and form a non-refractory liquid silicate containing said reactive alkaline earth and at least 42% silica, said intimate mixture containing no more silica than will combine at ultimate equilibrium with the reactive alkaline earth as the orthosilicate, and the total surface area of all nonvolatile constituents in said mixture being not more than 2.4 times the total surface area of the free and combined silica therein, heating the mixture to form and melt the non-refractory silicate in situ to coat the particles of basic granular material and further heating the mass to convert all the silica present into a refractory silicate of said alkaline earth, thereby bonding the granular particles into a consolidated and highly refractory mass.

5. A method of making refractory masses and shapes which comprises forming an intimate mixture of materials of two types, the first type consisting of basic refractory granular particles containing magnesia and at least 10% by weight of lime and having excess lime at least 6% by weight of the particles greater than that required to form calcium orthosilicate with any silica in said refractory granular particles, and the second type consisting of siliceous starting material for a non-refractory calcium-magnesium silicate, the siliceous starting material being finely divided relative to said granular particles, and the said intimate mixture of basic granular particles and siliceous starting material having a total surface area of the non-volatile constituents of all its particles not more than 2.4 times the total surface area of the free and combined silica in said mixture and having a weight ratio of lime to silica in said mixture at least substantially as great as that in calcium orthosilicate, heating the mixture to form and melt the nonrefractory calcium-magnesium silicate in situ and thereby coat the granular particles of refractory material, and further heating the mass to convert the non-refractory silicate by reaction with said excess lime into periclase and a calcium silicate at least substantially as basic as scram 21' the orthosilicate, and therebybond the irenirlaiparticles into a consolidated and highly refractory mass.

6. A method of making refractory masses and shapes which comprises forming an intimate mixture of materials of two types, the first type consisting of basic refractory 'granularparticle's being essentially magnesia with not more than by Weight of lime and having free magnesia least by weight of the particles in excess of that required to form magnesium orthosilicate with any silica and magnesium aluminate with any alumina in said granular particles, and the second type consisting of siliceous starting material for a non-refractory magnesium-aluminum silicate, the said starting material being finely divided relative to the said granular particles and the said intimate mixture of basic granular particles and siliceous starting material having a total surface area of the non-volatile constituents of all its particles not more than 2.4 times the total surface area of the free and combined silica in said mixture and having a weight ratio of magnesia to silica and alumina in said mix ture at least substantially 1.34 times the silica plus 0.40 times the alumina, heating the mixture to form and melt the non-refractory magnesiumaluminum silicate in situ and thereby coat the granular particles of refractory material, and urther heating the mass to convert the nonrefractory silicate by reaction with the said excess magnesia into forsterite, magnesium aluminate and periclase, and thereby bond the granular particles into a consolidated and highrefractory mass.

'7. A method as defined in claim 5 in which the proportions of lime, magnesia and silica in the starting material are essentially those of the eutectic melting at 1321" C. and containing 30.5 lime, 8.0 magnesia and 61.5% silica.

8. A method as defined in claim 5 in which the starting material for the non-refractory silicate contains magnesium silicate and calcium metasilicate in substantially equal proportions.

9. A method as defined in claim 5 in which free silica is a starting material for the nonrefractory silicate.

10. A method as defined in claim 9 in which the siliceous starting material contains burned dolomite.

11. A method as defined in claim 9 in which the siliceous starting material contains raw dolomite.

12. A method as defined in claim 1 in which the refractory granular particles to be bonded are raw dolomite.

13. A method as defined in claim 12 in which the siliceous starting material is finely ground free silica.

14. A method as defined in claim 12 in which the siliceous starting material contains calcium metasilicate and a silicate of magnesia.

15. A method as defined in claim 6 in which the non-refractory silicate contains magnesia, alumina and silica essentially in the proportions of the eutectic melting at about 1347" C. and containing 20.3 magnesia, 18.3 alumina and 61.4% silica.

16. A method as defined in claim 6 in which the siliceous starting material for the nonrefractory silicate contains a magnesium silicate and an aluminum silicate in substantially equal proportions.

1'7. A method as defined in claim 1 in which the non-refractory silicate constitutes 63-30% by weight of-th'e basic refractory granular particles:

to be bonded.

18. A method as defined tln claim 1'7 in which the non-refractorysilicate is substantially all molten at 1500" C.

19. A method as defined in claim 17 in which the non-refractory silicate issubstantially a binary eutectic and the bonding temperature is about 1550 C.

20. A method as defined in claim 1 in which at least-"50% by'weightpfthe refractory granular particles to be bonded are retained on a 20 mesh screen.

A 21. A method as defined in claim 20 in which the surface area per unit weight of the nonrefractory silicate is at least 15 times as great as that of the refractory granular particles to be bonded.

22. A batch material for refractory masses and shapes which consists of an intimate mixture of materials of two types, the first type consisting of basic granular refractory particles containing a reactive alkaline earth oxide, said reactive basic oxide being present in said refractory particles in amount greater than that required to form at ultimate equilibrium the orthosilicate with any silica in said refractory particles and the second type consisting of siliceous starting material for a non-refractory silicate of said alkaline earth, the siliceous constituents for the non-refractory silicate being finely divided relative to said granular refractory particles, the total surface area of the non-volatile constituents of all the particles in said mixture being not more than 2.4 times the total surface area of the free and combined silica therein, and said mixture containing no more silica than will combine at ultimate equilibrium with the reactive alkaline earth as the orthosilicate.

23. A batch material for refractory masses and shapes which consists of an intimate mixture of materials of two types, the first type being basic refractory granular particles containing magnesia and at least 10% by Weight of lime and having excess lime at least 6% by weight of the particles greater than that required to form calcium orthosilicate with any silica in said refractory particles, and the second type being siliceous starting material for a nonrefractory calcium-magnesium silicate, the siliceous starting material being finely divided relative to said granular particles, and the said intimate mixture of basic granular particles and siliceous starting material having a total surface area of the non-volatile constituents of all its particles not more than 2.4 times the total surface area of the free and combined silica in said mixture and having a weight ratio of lime to silica in said mixture at least substantially as great as that in calcium orthosilicate.

24. A batch material for refractory masses and shapes which consists of an intimate mixture of materials of two types, the first type being basic refractory granular particles consisting essentially of magnesia with not more than 5% by weight of lime and having free magnesia at least 10% by weight of the particles in excess of that required to form magnesium orthosilicate with any silica and magnesium aluminate with any alumina in said granular particles, and the second type being siliceous starting material for a non-refractory magnesium-aluminum silicate, the said starting material being finely divided relative to the said granular particles, and the said intimate mixture of basic granular particles aiid' siliceous starting material having Number Name fiate a total surface area of the non-volatile 0011- 1,206,771 Barr Nov. 28, 1916 stituents of all its particles not more than 2.4 1,210,431 Davison Jan. 2, 1917 times the total surface area of the free and 1,300,631 Meyer Apr. 15, 1919 combined silica in said mixture and having a 5 1,483,469 Meyer Feb. 12, 1924 weight ratio of magnesia to silica and alumina 1,751,234 Garnett Mar. 18, 1930 in said mixture at least substantially 1.34 times 2,015,446 Cape et a1 Sept. 24, 1935 the silica plus 0.40 times the alumina. 2,113,818 Sullivan Apr. 12, 1938 FRANK E. LATHE.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,160,085 Meyer Nov. 9, 1915 15 

